IP Library › Granted Patent US 12,491,759
Granted Patent B2
US 12,491,759 · App. 19/068,590 · Granted Dec 9, 2025

Vehicle frames for battery powered electric vehicles

Inventors: Saied Nusier (Canton, MI); Ridha Baccouche (Ann Arbor, MI); Saeed David Barbat (Novi, MI); Leonard Anthony Shaner (New Baltimore, MI); Srinivasan Sundararajan (Ann Arbor, MI); Rahul Arora (Birmingham, MI)
Assignee: Ford Global Technologies, LLC
B60K1/04B62D21/02B62D21/06B62D21/155B62D25/2018B60K2001/0411
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Quick Facts
Patent No.
US 12,491,759
App. No.
19/068,590
Granted
Dec 9, 2025
Kind
B2
Abstract

Vehicle frames for battery powered electric vehicles are disclosed. An example apparatus includes a vehicle frame including a first rail and a first rocker on a first side of the vehicle frame, and a second rail and a second rocker on a second side of the vehicle frame, the second side opposite the first side, a first backup rail coupled between the first rail and the first rocker, a second backup rail coupled between the second rail and the second rocker, a first brace extending between the first side and the second side, the first brace coupled to the first backup rail and at least one of the second backup rail or the second rocker, and a second brace extending between the first side and the second side, the second brace coupled to the second backup rail and at least one of the first backup rail or the first rocker.

Claims (41)

1 . An apparatus comprising:

a vehicle frame including:

a first rail and a first rocker on a first side of the vehicle frame; and

a second rail and a second rocker on a second side of the vehicle frame, the second side opposite the first side;

a first backup rail coupled between the first rail and the first rocker;

a second backup rail coupled between the second rail and the second rocker;

a first brace extending between the first side and the second side, the first brace coupled to the first backup rail and at least one of the second backup rail or the second rocker; and

a second brace extending between the first side and the second side, the second brace coupled to the second backup rail and at least one of the first backup rail or the first rocker.

2 . The apparatus of claim 1 , wherein the first backup rail extends between a first inner elbow and a first outer elbow on the first side of the vehicle frame, and the second backup rail extends between a second inner elbow and a second outer elbow on the second side of the vehicle frame.

3 . The apparatus of claim 2 , wherein the first brace is coupled to the first backup rail at the first inner elbow and the second brace is coupled to the second backup rail at the second outer elbow.

4 . The apparatus of claim 3 , wherein the first brace is coupled to the second backup rail between the second inner elbow and the second outer elbow, and the second brace is coupled to the first backup rail between the first inner elbow and the first outer elbow.

5 . The apparatus of claim 1 , wherein the first brace and the second brace include metal tubes extending between the first side and the second side of the vehicle frame.

6 . The apparatus of claim 1 , wherein the first brace is coupled to the second brace at an intersection between the first brace and the second brace.

7 . The apparatus of claim 6 , wherein the first brace and the second brace are at least one of crimped or flattened at the intersection.

8 . An apparatus comprising:

a vehicle frame including:

a first inner elbow and a first outer elbow on a first side of the vehicle frame; and

a second inner elbow and a second outer elbow on a second side of the vehicle frame, the second side opposite the first side;

a first backup rail coupled to the first side of the vehicle frame and extending across the first inner elbow and the first outer elbow;

a second backup rail coupled to the second side of the vehicle frame and extending across the second inner elbow and the second outer elbow;

a first cross-member coupled to the first backup rail at the first inner elbow and to the second side of the vehicle frame; and

a second cross-member coupled to the second backup rail at the second inner elbow and to the first side of the vehicle frame.

9 . The apparatus of claim 8 , wherein the first cross-member is coupled to the second side of the vehicle frame at the second backup rail between the second inner elbow and the second outer elbow, and the second cross-member is coupled to the first side of the vehicle frame at the first backup rail between the first inner elbow and the first outer elbow.

10 . The apparatus of claim 9 , wherein the first cross-member is coupled to the second backup rail at a first midpoint of the second backup rail, and the second cross-member is coupled to the first backup rail at a second midpoint of the first backup rail.

11 . The apparatus of claim 8 , wherein the vehicle frame includes a first rail and a first rocker on the first side of the vehicle frame and a second rail and a second rocker on the second side of the vehicle frame, the first cross-member coupled to the second rocker, the second cross-member coupled to the first rocker.

12 . The apparatus of claim 8 , wherein the first cross-member and the second cross-member include metal tubes extending between the first side and the second side of the vehicle frame.

13 . The apparatus of claim 8 , wherein the first cross-member is coupled to the second cross-member at an intersection between the first cross-member and the second cross-member.

14 . The apparatus of claim 13 , wherein the first cross-member and the second cross-member are at least one of crimped or flattened at the intersection.

15 . An apparatus comprising:

a vehicle frame including:

a first rail and a first rocker on a first side of the vehicle frame; and

a second rail and a second rocker on a second side of the vehicle frame, the second side opposite the first side;

a backup rail coupled to the first side of the vehicle frame and extending between the first rail and the first rocker, the backup rail to transfer a first portion of a longitudinal load on the first rail from the first rail to the first rocker; and

a cross-member coupled to the second side of the vehicle frame and to the backup rail at a bend of the first rail, the cross-member to transfer a second portion of the longitudinal load from the first rail to the second side of the vehicle frame.

16 . The apparatus of claim 15 , wherein the backup rail is a first backup rail, the cross-member is a first cross-member, the bend is a first bend, the longitudinal load is a first longitudinal load, and further including:

a second backup rail coupled to the second side of the vehicle frame and extending between the second rail and the second rocker, the second backup rail to transfer a third portion of a second longitudinal load on the second rail from the second rail to the second rocker; and

a second cross-member coupled to the first side of the vehicle frame and to the second backup rail at a second bend of the second rail, the second cross-member to transfer a fourth portion of the second longitudinal load from the second rail to the first side of the vehicle frame.

17 . The apparatus of claim 16 , wherein the first cross-member is coupled to the second side of the vehicle frame at the second rocker, and the second cross-member is coupled to the first side of the vehicle frame at the first rocker.

18 . The apparatus of claim 16 , wherein the first cross-member is coupled to the second side of the vehicle frame at the second backup rail, and the second cross-member is coupled to the first side of the vehicle frame at the first backup rail.

19 . The apparatus of claim 16 , wherein the first cross-member is coupled to the second cross-member at an intersection between the first cross-member and the second cross-member.

20 . The apparatus of claim 19 , wherein the first cross-member and the second cross-member are at least one of crimped or flattened at the intersection.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 4, 2025
From: NUSIER, SAIED; BACCOUCHE, RIDHA; BARBAT, SAEED DAVID; SHANER, LEONARD ANTHONY; SUNDARARAJAN, SRINIVASAN; ARORA, RAHUL
To: FORD GLOBAL TECHNOLOGIES, LLC
Reel/Frame 070733/0765 →
Continuity (3)
Continuation 18508948 · Nov 14, 2023
Continuation 17204610 · Mar 17, 2021
Related Publication 20250196610A1 · Jun 19, 2025
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